Fuselage
Aircraft Complete!
Conducted flight test card C and D along with high speed taxi test to verify AeroInjector tuning and ability for engine to generate static RPM. After letting engine parameters stabilize, recorded data for test card C and testing mixture, fuel valve, and magneto shut-off methods. With help from Hannah, performed wet compass deviation check and…
Aircraft Weight and Balane
Completed weighing process for initial weight and balance of aircraft. Started by leveling aircraft with tail wheel stand and aligning aircraft to floor squares. Ran tape measure along centerline of the aircraft and dropped plumb bob from spinner to set tip of spinner at 0″ (datum). Also dropped plumb bob from tailwheel to ensure tape…
Aircraft Weighing Prep
Made preparations for weighing aircraft by draining fuel from fuel tank. Cut small ramps out of 1″ x 8″ wood on a 45 degree angle; thickness should allow for aircraft main tires to roll right onto scales without tipping them up. Made tailwheel scale stand out of scrap wood to hold aircraft approximately level during…
Fuselage Floors – Part 3
Finished riveting aft fuselage floor. Riveted forward fuselage floor working one line of rivets at a time to make sure proper sizes were used. Installed plug in aft fuselage floor to protect tail spring bolt. Riveted data plate on LH fuselage side underneath horizontal stabilizer. Hours Worked: 2.65
Fuselage Floors – Part 2
Began final installing fuselage floors by installing AN525 hardware in the forward lower engine mounts, the aft splice plates, and the tailwheel mount bulkhead. Final installed antennas, autopilot servos, seat pans, fuselage side panels, and seats. Began riveting aft fuselage. Replaced missing canopy alignment pin and added locknuts to cover protrusions and potential of pins…
Baggage Compartment Wrap-up
Cut 0.025″ aluminum sheet and extra SNX-Z03-02 stock to create elevator pushrod cover in baggage compartment. Riveted pieces together then installed Velcro strips on baggage compartment floor and cover. Installed pushrod tunnel and verified no interference with flight controls. Cut rear baggage compartment covers out of 0.025″ sheet and attached to #2 former structure with…
Fuselage Floors – Part 1
Aligned aft fuselage floor and clecoed to fuselage. Riveted forward floor stiffener and gussets to firewall and forward spar tunnel zee. Clecoed forward fuselage floor onto fuselage ensuring gussets and spacers stayed aligned properly. Floor now ready to rivet. Hours Worked: 0.87
Safety Equipment Mounting
Mounted fire extinguisher and crash hammer to forward fuselage with Velcro straps and adhesive pads. Manufactured rudder trim tab from scrap aluminum. Hours Worked: 0.79
Seatbelt Installation – Part 2
Updrilled shoulder harness attach points to 5/16″ and bolted seatbelt shoulder harnesses with AN5 hardware. Applied torque seal to bolts. Hours Worked:0.42
Fuselage Side Panels and Wrap-up
Tweaked fitment of RH side panel by trimming a little more off of the rear side of the panel. Attached Velcro strips to back and bottom of side panel and upper longeron and seat pans. Installed side panel and checked fitment. Rough trimmed LH side panel from ABS sheet and went through a couple iterations…
Fuselage Side Panels – Part 2
Trimmed lower and upper seat pans for better clearance of wire bundles and side panels. Test fit RH side panel and trimmed a couple more places for better wire clearance. Hours Worked: 1.00
Hole Filling
Finished fuselage conversion steps by applying jb weld to holes from original side skin left over from conversion process. Hours Worked: 0.14
